Apparatus and method for degrading a web in the machine direction while preserving cross-machine direction strength

ABSTRACT

An embossing system for embossing and perforating at least a portion of a web is provided comprising a first embossing roll having embossing elements and at least a second embossing roll having embossing elements, wherein the elements of the first and second embossing rolls define perforate nips for embossing and perforating the web and wherein at least a predominate number of the perforate nips are substantially oriented in the cross-machine direction. Moreover, substantially all of the nips defined by the embossing elements of the first and second embossing rolls can be substantially oriented in the cross-machine direction. Further, the cross-machine embossing elements are at an angle of about 85° to 95° from the machine direction.

FIELD OF THE INVENTION

[0001] The present invention relates to an apparatus and method forembossing a moving web of material, such as paper, to create afunctional controlled degradation of the machine direction strength ofthe web while limiting degradation of the cross-machine directionstrength of the web. In particular, the present invention relates to anapparatus and method for embossing a moving web using an embossingsystem having perforate embossing elements oriented to defineperforating nips substantially oriented in the cross-machine directionto improve the flexibility, feel, bulk, and absorbency of the paper.

BACKGROUND OF THE INVENTION

[0002] Embossing is the act of mechanically working a substrate to causethe substrate to conform under pressure to the depths and contours of apatterned embossing roll. Generally the web is passed between a pair ofembossing rolls that, under pressure, form contours within the surfaceof the web. During an embossing process, the roll pattern is impartedonto the web at a certain pressure and/or penetration. In perforateembossing the embossing elements are configured such that at least aportion of the web located between the embossing elements is perforated.As used herein, generally, “perforated” refers to the existence ofeither (1) a macro-scale through aperture in the web or (2) when amacro-scale through aperture does not exist, at least incipient tearingsuch as would increase the transmittivity of light through a smallregion of the web or would decrease the machine direction strength of aweb by at least 15% for a given range of embossing depths.

[0003] Embossing is commonly used to modify the properties of a web tomake a final product produced from that web more appealing to theconsumer. For example, embossing a web can improve the softness,absorbency, and bulk of the final product. Embossing can also be used toimpart an appealing pattern to a final product.

[0004] Embossing is carried out by passing a web between two or moreembossing rolls, at least one of which carries the desired embosspattern. Known embossing configurations include rigid-to-resilientembossing and rigid-to-rigid embossing.

[0005] In a rigid-to-resilient embossing system, a single or multi-plysubstrate is passed through a nip formed between a roll whosesubstantially rigid surface contains the embossing pattern as amultiplicity of protuberances and/or depressions arranged in anaesthetically-pleasing manner, and a second roll, whose substantiallyresilient surface can be either smooth or also contain a multiplicity ofprotuberances and/or depressions which cooperate with the rigid surfacedpatterned roll. Commonly, rigid rolls are formed with a steel body whichis either directly engraved upon or which can contain a hardrubber-covered, or other suitable polymer, surface (directly coated orsleeved) upon which the embossing pattern is formed by any convenientmethod such as, for example, being laser engraved. The resilient rollmay consist of a steel core provided with a resilient surface, such asbeing directly covered or sleeved with a resilient material such asrubber, or other suitable polymer. The rubber coating may be eithersmooth or engraved with a pattern. The pattern on the resilient roll maybe either a mated or a non-mated pattern with respect to the patterncarried on the rigid roll.

[0006] In the rigid-to-rigid embossing process, a single-ply ormulti-ply substrate is passed through a nip formed between twosubstantially rigid rolls. The surfaces of both rolls contain thepattern to be embossed as a multiplicity of protuberances and/ordepressions arranged into an aesthetically-pleasing manner where theprotuberances and/or depressions in the second roll cooperate with thosepatterned in the first rigid roll. The first rigid roll may be formed,for example, with a steel body which is either directly engraved upon orwhich can contain a hard rubber-covered, or other suitable polymer,surface (directly coated or sleeved) upon which the embossing pattern isengraved by any conventional method, such as by laser engraving. Thesecond rigid roll can be formed with a steel body or can contain a hardrubber covered, or other suitable polymer, surface (directly coated orsleeved) upon which any convenient pattern, such as a matching or matedpattern, is conventionally engraved or laser-engraved. In perforateembossing, a rigid-to-rigid embossing system is typically used. However,a rigid-resilient configuration can also be used for perforateembossing.

[0007] When substantially rectangular embossing elements have beenemployed in perforate embossing, the embossing elements on the embossingrolls have generally been oriented so that the long direction axis,i.e., the major axis, of the elements is in the machine direction. Thatis, the major axis of the elements is oriented to correspond to thedirection of the running web being embossed. These elements are referredto as machine direction elements. As a result, the elements produceperforations which extend primarily in the machine direction andundesirably decrease the strength of the web in the cross-machinedirection. This orientation improves absorbency and softness, but candegrade, i.e., reduce the strength of, the web primarily in thecross-machine direction while less significantly degrading the strengthof the web in the machine direction. As a result, the tensile strengthof the web in the cross-machine direction is reduced relatively more, ona percentage basis, than that of the machine direction. In addition, thecross-machine direction strength of the base sheet is typically lessthan that of the machine direction strength. As a result, by embossingwith machine direction elements, the cross-machine direction strength iseven further weakened and, accordingly, because the finished productwill fail in the weakest direction, the product will be more likely tofail when stressed in the cross-machine direction. Often, it ispreferred that the web is “square,” i.e., has a machinedirection/cross-machine direction tensile ratio close to 1.0.

[0008] Cross-machine direction tensile strength can be associated withconsumer preference for paper toweling. In particular, consumers prefera strong towel, of which cross-machine direction and machine directionstrength are two components. Because the un-embossed base sheet istypically much stronger in the machine direction than the cross-machinedirection, a process is desired which results in both improvedabsorbency and softness without sustaining excessive losses incross-machine direction tensile strength.

[0009] The present invention addresses at least the above describedproblem by providing at least two embossing rolls, wherein at least aportion of the elements are oriented to provide perforating nips whichare substantially in the cross-machine direction and are configured toperforate the web, thereby allowing relatively greater degradation,i.e., a reduction of strength, of the web in the machine direction whilepreserving more of the cross-machine direction strength.

[0010] Further advantages of the invention will be set forth in part inthe description which follows and in part will be apparent from thedescription or may be learned by practice of the invention. Theadvantages of the invention may be realized and attained by means of theinstrumentalities and combinations particularly pointed out in theappended claims.

SUMMARY OF THE INVENTION

[0011] As embodied and broadly described herein, the invention includesan embossing system for embossing and perforating at least a portion ofa web comprising a first embossing roll having embossing elements and atleast a second embossing roll having embossing elements, whereinjuxtaposition and engagement of the first and second embossing rollsdefine a plurality of perforate nips for embossing and perforating theweb and wherein at least a predominate number of the embossing elementsare configured so as to produce perforating nips which are substantiallyoriented in the cross-machine direction. In one embodiment, theinvention further includes an embossing system wherein substantially allof the embossing elements of the first and second embossing rollsproduce perforating nips which are substantially oriented in thecross-machine direction. Further, in a preferred embodiment, thecross-machine embossing elements are at an angle of 85 to 95° from themachine direction.

[0012] In another embodiment, the invention includes an embossing systemfor embossing at least a portion of a web comprising a first embossingroll and at least a second embossing roll, wherein each of the first andsecond embossing rolls has at least one juxtaposable embossing elementcapable of producing a perforating nip substantially oriented in thecross-machine direction, thereby defining a cross-machine directionperforate nip between the cross-machine direction elements for embossingand perforating the web, and wherein at least a substantial portion ofthe cross-machine direction elements have at least the ends beveled.

[0013] In yet another embodiment, the invention includes an embossingsystem for embossing and perforating at least a portion of a webcomprising a first embossing roll and at least a second embossing roll,wherein each of the first and second embossing rolls has at least onejuxtaposable element capable of producing a perforating nipsubstantially oriented in the cross-machine direction, thereby defininga cross-machine direction perforate nip between the cross-machinedirection elements for embossing and perforating the web, and whereinthe cross-machine direction elements have sidewall angles, the anglebetween the sidewall and the radial direction on the cross-machinedirection sides of the element, juxtaposed so as to be capable ofproducing a shear line, of less than about 20°. In one embodiment thecross-machine direction elements have cross-machine direction sidewallangles of less than about 17°. In another embodiment the cross-machinedirection elements have cross-machine direction sidewall angles of lessthan about 14°. In a preferred embodiment, the cross-machine directionelements have cross-machine direction sidewall angles of less than 11°.In a further preferred embodiment the cross-machine direction elementshave cross-machine direction sidewall angles of from about 7° to 11°.

[0014] In yet another embodiment, the invention includes a method forembossing and perforating at least a portion of a web comprisingproviding a first embossing roll having embossing elements and providingat least a second embossing roll having embossing elements, wherein atleast a predominate number of the embossing elements, when juxtaposedsuch that they are capable of producing perforate nips, aresubstantially oriented in the cross-machine direction and wherein thefirst and second embossing rolls define a perforate nip for embossingand perforating the web and passing the web between the first and secondembossing rolls wherein the first and second embossing rolls areconfigured to result in an element clearance that will achieve anon-picking clearance while achieving at least a 15% reduction in themachine direction tensile strength of the web. We have found that it isdesirable to exert special care to control the circumferential alignmentof the two rolls to alleviate picking which may result from drift causedby local variances in roll diameter or gearing from the ideal.

[0015] In still yet another embodiment, the invention includes a methodfor reducing the tensile ratio of a web by embossing and perforating theweb comprising passing a web through an embossing system, wherein theembossing system comprises a first embossing roll having embossingelements and at least a second embossing roll having embossing elements,wherein the first and second embossing rolls define a plurality ofperforating nips for embossing and perforating the web and wherein atleast a predominant number of the perforating nips which aresubstantially oriented in the cross-machine direction. In oneembodiment, the invention further includes an embossing system whereinsubstantially all of the embossing elements of the first and secondembossing rolls produce perforating nips which are substantiallyoriented in the cross-machine direction. Further, in a preferredembodiment, the cross-machine embossing elements are at an angle of85-95° from the machine direction.

[0016] In yet another embodiment, the invention includes a method forreducing the tensile ratio of a web by embossing and perforating the webcomprising passing a web through an embossing system, wherein theembossing system comprises a first embossing roll and at least a secondembossing roll, wherein each of the first and second embossing rolls hasat least one juxtaposable embossing element capable of producing aperforating nip substantially oriented in the cross-machine direction,thereby defining a cross-machine direction perforate nip between thecross-machine direction elements for embossing and perforating the weband wherein at least a substantial portion of the cross-machinedirection elements have at least the ends beveled.

[0017] In still yet another embodiment, the invention includes a methodfor reducing the tensile ratio of a web by embossing and perforating theweb comprising, passing a web through an embossing system, wherein theembossing system comprises a first embossing roll and at least a secondembossing roll, wherein each of the first and second embossing rolls hasat least one juxtaposable embossing element capable of producing aperforating nip substantially oriented in the cross-machine direction,thereby defining a cross-machine direction perforate nip between thecross-machine direction elements for embossing and perforating the weband wherein the cross-machine direction elements have cross-machinedirection sidewall angles of less than about 20°. In one embodiment thecross-machine direction elements have cross-machine direction sidewallangles of less than about 17°. In another embodiment the cross-machinedirection elements have cross-machine direction sidewall angles of lessthan about 14°. It is preferred that the cross-machine directionelements have cross-machine direction sidewall angles of less than about11°. It is further preferred that the cross-machine direction elementshave cross-machine direction sidewall angles of from about 7° to 11°.

[0018] In another embodiment, the invention includes a method forreducing the tensile ratio of a web by embossing and perforating the webcomprising passing a web through an embossing system, wherein theembossing system comprises a first embossing roll having embossingelements and at least a second embossing roll having embossing elements,wherein the first and second embossing rolls define a perforate nip forembossing and perforating the web and wherein the first and secondembossing rolls are configured to result in an element clearance thatwill achieve a non-picking clearance.

[0019] The invention further includes a perforate embossed web having aplurality of cross-machine direction oriented perforations wherein theembossed web has a tensile ratio of less than about 1.2. The inventionfurther includes a perforate embossed web having a transluminance ratio(as defined hereinafter) of at least 1.005. Still further, the inventionincludes a wet-laid cellulosic perforate embossed web having perforateembossments extending predominately in the cross-machine direction.

[0020] Finally, the invention includes a method of embossing andperforating the web comprising passing a web through an embossingsystem, wherein the embossing system comprises a first embossing rollhaving embossing elements and at least a second embossing roll havingembossing elements, wherein the first and second embossing rolls definea plurality of perforate nips for embossing and perforating the web, andwherein the tensile ratio of the web is reduced.

[0021] The accompanying drawings, which are incorporated herein andconstitute a part of this specification, illustrate an embodiment of theinvention, and, together with the description, serve to explain theprinciples of the invention.

BRIEF DESCRIPTION OF THE DRAWINGS

[0022] FIGS. 1A-D illustrates embossing rolls having cross-machinedirection elements according to an embodiment of the present invention.

[0023]FIG. 2 illustrates cross-machine direction elements according toanother embodiment of the present invention.

[0024]FIG. 3 illustrates cross-machine direction elements according toanother embodiment of the present invention.

[0025]FIG. 4 illustrates the alignment of the cross-machine directionelements according to an embodiment of the present invention.

[0026]FIG. 5 illustrates the alignment of the cross-machine directionelements according to another embodiment of the present invention.

[0027]FIG. 6 illustrates the alignment of the cross-machine directionelements according to another embodiment of the present invention.

[0028]FIG. 7 illustrates the alignment of the cross-machine directionelements according to yet another embodiment of the present invention.

[0029]FIG. 8 is a photomicrograph illustrating the effect ofcross-machine direction elements on a web according to an embodiment ofthe present invention.

[0030]FIG. 9 is a photomicrograph illustrating the effect ofcross-machine direction elements on a web according to anotherembodiment of the present invention.

[0031]FIG. 10 illustrates the effect of cross-machine direction elementson a web according to yet another embodiment of the present invention.

[0032]FIG. 11 illustrates the effect of cross-machine direction elementson a web according to yet another embodiment of the present invention.

[0033] FIGS. 12A-C are side views of the cross-machine directionelements of embodiments of the present invention having differing wallangles and illustrating the effect of the differing wall angles.

[0034] FIGS. 13A-C are side views of the cross-machine directionelements of embodiments of the present invention having differing wallangles and illustrating the effect of the differing wall angles.

[0035] FIGS. 14A-C are side views of the cross-machine directionelements of yet another embodiment of the present invention havingdiffering wall angles and illustrating the effect of the differing wallangles.

[0036]FIG. 15 depicts a transluminance test apparatus.

[0037] FIGS. 16A-B illustrate embossing rolls having both cross-machinedirection and machine direction elements according to an embodiment ofthe present invention.

[0038] FIGS. 17A-C illustrate the effects of over embossing a webportion in the machine direction and cross-machine direction when usingrigid to resilient embossing as compared to perforate embossing a web asin FIG. 17D.

DETAILED DESCRIPTION

[0039] Reference will now be made in detail to the preferred embodimentsof the present invention, examples of which are illustrated in theaccompanying drawings.

[0040] The present invention can be used to emboss a variety of types ofwet-laid cellulosic webs including paper, and the like. The webs can becontinuous or of a fixed length. Moreover, embossed webs can be used toproduce any art recognized product, including, but not limited to, papertowels, napkins, tissue, or the like. Moreover, the resulting productcan be a single ply or a multi-ply paper product, or a laminated paperproduct having multiple plies. In addition, the present invention can beused with a web made from virgin furnish, recycled furnish, or a webcontaining both virgin and recycled furnish, synthetic fibers, or anycombination thereof.

[0041] In accordance with the invention, as broadly described, theconverting process includes an embossing system of at least twoembossing rolls, the embossing rolls defining at least one nip throughwhich a web to be embossed is passed. The embossing elements arepatterned to create perforations in the web as it is passed through thenip.

[0042] Generally, for purposes of this invention, perforations arecreated when the strength of the web is locally degraded between twobypassing embossing elements resulting in either (1) a macro scalethrough-aperture or (2) in those cases where a macro scalethrough-aperture is not present, at least incipient tearing, where suchtearing would increase the transmittivity of light through a smallregion of the web or would decrease the machine direction strength of aweb by at least 15% for a given range of embossing depths. Graph 1depicts a comparison of the effects on reduction of strength in themachine direction when perforate embossing a web, as defined herein, andnon-perforate embossing a web. In particular, a conventional wet pressedbase sheet was perforate embossed between two steel rolls. The same basesheet was non-perforate embossed in a rubber to steel configuration. Inaddition, a through-air-dried base sheet was also perforate andnon-perforate embossed. The reduction in machine direction strength wasmeasured for each of the sheets. The results are plotted on Graph 1.

[0043] As shown in Graph 1, when non-perforate embossing either a CWP orTAD web to depths of up to 40 mils, the reduction of paper strength inthe machine direction is less than 5%. And, when non-perforate embossingeither of the CWP or TAD webs at a depth of 80 mils, the reduction ofstrength of the web is less than 15%. When perforate embossing a web asdisclosed in this invention, a greater reduction in strength of the webcan be achieved. In the example set forth herein, strength reductions ofgreater than 15% are achieved when perforate embossing at depths of atleast about 15 mils as compared to rubber to steel embossing which canresult in these strength losses at emboss depths of over 60 mils.Accordingly, for purposes of this invention, perforation is specificallydefined as locally degrading the strength of the web between twobypassing embossing elements resulting in either (1) the formation of amacro scale through-aperture or (2) when a macro scale through-apertureis not formed, at least incipient tearing, where such tearing wouldeither increase the transmittivity of light through a small region ofthe web or would decrease the machine direction strength of a web by atleast the percentages set forth in Graph 1, wherein the “at least”percentages are indicated by the dashed line.

[0044] Not being bound by theory, we believe that the superior strengthreduction results achieved using the present invention are due to thelocation of the local degradation of the web when perforate embossing ascompared to when non-perforate embossing. When a web is embossed, eitherby perforate or non-perforate methods, the portion of the web subject tothe perforate or non-perforate nip is degraded. In particular, as a webpasses through a non-perforate nip for embossing, the web is stressedbetween the two embossing surfaces such that the fiber bonds arestretched and sometimes, when the web is over embossed, which is notdesired when non-perforate embossing a web, the bonds are torn orbroken. When a web is passed through a perforate nip, the web fiberbonds are at least incipiently torn by the stresses caused by the twobypassing perforate elements. As stated above, however, one differencebetween the two methods appears to be in the location of the at leastincipient tearing.

[0045] When a web is over-embossed in a rubber to steel configuration,the male steel embossing elements apply pressure to the web and therubber roll, causing the rubber to deflect away from the pressure, whilethe rubber also pushes back. As the male embossing elements roll acrossthe rubber roll during the embossing process, the male elements pressthe web into the rubber roll which causes tension in the web at the areaof the web located at the top edges of the deflected rubber roll, i.e.,at the areas at the base of the male embossing elements. When the web isover-embossed, tearing can occur at these high-tension areas. Moreparticularly, FIGS. 17A-C depict rubber to steel embossing of a web atvarious embossing depths. FIG. 17A depicts embossing of a web atapproximately 0 mils. In this configuration the rubber roll pins the webat the points where the web contacts the steel roll element tops.Typically no tearing will occur in this configuration. In FIG. 17B,where the embossing depth is approximately the height of the steelembossing element, the web is pinned at the element tops and at a pointbetween the bases of the adjacent steel elements. As with theconfiguration depicted in FIG. 17A, tearing does not typically occur inthis configuration for conventional embossing procedures. FIG. 17Cdepicts an embossing depth comparable to or greater than the height ofthe steel element. In this configuration, the “free span” of the web,i.e., the sections of the web that are not pinned between the rubber andsteel rolls, becomes shorter as the rubber material fills the areabetween the adjacent elements. When web rupturing occurs, it tends tooccur near the last location where web movement is possible; that is,the area of degradation 40 is the last area that is filled by the rubbermaterial, namely the corners where the bases of the elements meet thesurface of the emboss roll.

[0046] When a web is perforate embossed, on the other hand, the areas ofdegradation 42, as shown in FIG. 17D, are located along the sides of theperforate embossing element. It appears that as a result of thisdifference the degradation of the web and the resultant reduction of webstrength is dramatically different.

[0047] In one embodiment according to the present invention, theembossing rolls have substantially identical embossing element patterns,with at least a portion of the embossing elements configured such thatthey are capable of producing perforating nips which are capable ofperforating the web. As the web is passed through the nip, an embossingpattern is imparted on the web. It is preferred that the embossing rollsbe either steel or hard rubber, or other suitable polymer. The directionof the web as it passes through the nip is referred to as the machinedirection. The transverse direction of the web that spans the embossroll is referred to as the cross-machine direction. It is furtherpreferred that a predominant number, i.e., at least 50% or more, of theperforations are configured to be oriented such that the major axis ofthe perforation is substantially oriented in the cross-machinedirection. An embossing element is substantially oriented in thecross-machine direction when the long axis of the perforation nip formedby the embossing element is at an angle of from about 60° to 120° fromthe machine direction of the web.

[0048] In an embodiment according to the present invention, and as shownin FIG. 1, the converting process includes an embossing system 20 of twoembossing rolls 22 defining a nip 28 through which the web 32 to beembossed is passed. According to one embodiment, the embossing rolls 22are matched embossing rolls. The embossing rolls can be, for example,either steel or hard rubber, or other suitable polymer. The embossingrolls 22 have at least a portion of embossing elements 34 oriented suchthat the major axis of the elements 34 is in the cross-machinedirection, i.e., the elements are in the cross-machine direction. It ispossible to envisage configurations in which perforations extending inthe cross-machine direction are formed by elements which are longer inthe machine direction, although such a configuration would normally besub-optimal as it would compromise the overall number of perforationswhich could be formed in the web. Accordingly, when we discuss elementsoriented in the cross-machine direction, we are referring to elementsthat are configured such that the orientation of the perforation formedby those elements extends in the cross-machine direction, irrespectiveof the shape of the remainder of the element not contributing to theshape of the nip, whether the element be male or female. While theembossing rolls 22 can also have embossing elements oriented such thatthe major axis of the elements is in the machine direction, apredominant number, i.e., at least 50% or more, of the elements 34should be oriented such that they are capable of producing perforatingnips extending in the cross-machine direction. In another embodiment,substantially all, i.e., at least more than 75%, of the elements 34 areoriented such that they are capable of producing perforating nipsextending in the cross-machine direction. In yet another embodiment, allof the elements are oriented in the cross-machine direction. Moreover,at least about 25% of the cross-machine direction elements areperforating elements. In a preferred embodiment, all of thecross-machine direction elements are perforating elements. Thus, whenthe web passes through the embossing rolls 22, at least a portion of thecross-machine direction elements are aligned such that the web isperforated such that at least a portion of the perforations aresubstantially oriented in the cross-machine direction.

[0049] The end product characteristics of a cross-machine directionperforated embossed product can depend upon a variety of factors of theembossing elements that are imparting a pattern on the web. Thesefactors can include one or more of the following: embossing elementheight, angle, shape, including sidewall angle, spacing, engagement, andalignment, as well as the physical properties of the rolls, base sheet,and other factors. Following is a discussion of a number of thesefactors.

[0050] An individual embossing element 34 has certain physicalproperties, such as height, angle, and shape, that affect the embossingpattern during an embossing process. The embossing element can be eithera male embossing element or a female embossing element. The height of anelement 34 is the distance the element 34 protrudes from the surface ofthe embossing roll 22. It is preferred that the embossing elements 34have a height of at least about 15 mils. In one embodiment according tothe present invention, the cross-machine direction elements 34 have aheight of at least about 30 mils. In another embodiment of the presentinvention, the cross-machine direction elements 34 have a height ofgreater than about 45 mils. In yet another embodiment of the invention,the cross-machine elements have a height of greater than about 60 mils.In yet another embodiment, a plurality of the elements 34 on the rollhave at least two regions having a first region having elements having afirst height and at least a second region having elements having asecond height. In a preferred embodiment, the elements 34 have a heightof between about 30 to 65 mils. Those of ordinary skill in the art willunderstand that there are a variety of element heights that can be used,depending upon a variety of factors, such as the type of web beingembossed and the desired end product.

[0051] The angle of the cross-machine direction elements 34substantially defines the direction of the degradation of the web due tocross-machine perforate embossing. When the elements 34 are oriented atan angle of about 90° from the machine direction, i.e., in the absolutecross-machine direction, the perforation of the web can be substantiallyin the direction of about 90° from the machine direction and, thus, thedegradation of web strength is substantially in the machine direction.On the other hand, when the elements 34 are oriented at an angle fromthe absolute cross-machine direction, degradation of strength in themachine direction will be less and degradation of strength in thecross-machine direction will be more as compared to a system where theelements 34 are in the absolute cross-machine direction.

[0052] The angle of the elements 34 can be selected based on the desiredproperties of the end product. Thus, the selected angle can be any anglethat results in the desired end product. In an embodiment according tothe present invention, the cross-machine direction elements 34 can beoriented at an angle of at least about 60° from the machine direction ofthe web and less than about 120° from the machine direction of the web.In another embodiment, the cross-machine direction elements 34 areoriented at an angle from at least about 75° from the machine directionof the web and less than about 105° from the machine direction of theweb. In yet another embodiment, the cross-machine direction elements 34are oriented at an angle from at least about 80° from the machinedirection of the web and less than about 100° from the machine directionof the web. In a preferred embodiment, the cross-machine directionelements 34 are oriented at an angle of about 85-95° from the machinedirection.

[0053] A variety of element shapes can be successfully used in thepresent invention. The element shape is the “footprint” of the topsurface of the element, as well as the side profile of the element. Itis preferred that the elements 34 have a length (in the cross-machinedirection)/width (in the machine direction) (L/W) aspect ratio of atleast greater than 1.0, however while noted above as sub-optimal, theelements 34 can have an aspect ratio of less than 1.0. It is furtherpreferred that the aspect ratio be about 2.0. One element shape that canbe used in this invention is a hexagonal element, as depicted in FIG. 2.Another element shape, termed an oval, is depicted in FIG. 3. For ovalelements, it is preferred that the ends have radii of at least about0.003″ and less than about 0.030″ for at least the side of the elementforming a perforate nip. In one embodiment, the end radii are about0.0135″. Those of ordinary skill in the art will understand that avariety of different embossing element shapes, such as rectangular, canbe employed to vary the embossing pattern.

[0054] In one embodiment, at least a portion of the elements 34 arebeveled. In particular, in one embodiment the ends of a portion of theelements 34 are beveled. Oval elements with beveled edges are depictedin FIG. 1. By beveling the edges, the disruptions caused by theembossing elements can be better directed in the cross-machinedirection, thereby reducing cross-machine direction degradation causedby the unintentional machine direction disruptions. The bevel dimensionscan be from at least about 0.010″ to at least about 0.025″ long in thecross-machine direction and from at least about 0.005″ to at least about0.015″ in the z-direction. Other elements, such as hexagonal elements,can be beveled, as well.

[0055] The cross-machine direction sidewall of the elements 34 definesthe cutting edge of the elements 34. According to one embodiment of thepresent invention, the cross-machine direction sidewalls of the elements34 are angled. As such, when the cross-machine direction sidewalls areangled, the base of the element 34 has a width that is larger than thatof the top of the element. It is preferred that the cross-machinedirection sidewall angle be less than about 20°. It is still furtherpreferred that the cross-machine direction sidewall angle be less thanabout 17°. It is still further preferred that the cross-machinedirection sidewall angle be less than about 14°. Finally, in a preferredembodiment the cross-machine direction sidewall angle is less than about11°. It is further preferred that the cross-machine direction sidewallangle be between about 7° and 11°.

[0056] When the opposing elements 34 of the embossing rolls are engagedwith each other during an embossing process, the effect on the web isimpacted by at least element spacing, engagement, and alignment. Whenperforate embossing, the elements 34 are spaced such that the clearancebetween the sidewalls of elements of a pair, i.e., one element 34 fromeach of the opposing embossing rolls 22, creates a nip that perforatesthe web as it is passed though the embossing rolls 22. If the clearancebetween elements 34 on opposing rolls is too great, the desiredperforation of the web may not occur. On the other hand, if theclearance between elements 34 is too little, the physical properties ofthe finished product may be degraded excessively or the embossingelements themselves could be damaged. The required level of engagementof the embossing rolls is at least a function of the embossing pattern(element array, sidewall angle, and element height), and the base sheetproperties, e.g., basis weight, caliper, strength, and stretch. At aminimum, it is preferred that the clearances between the sidewalls ofthe opposing elements of the element pair be sufficient to avoidinterference between the elements. In one embodiment, the minimumclearance is about a large fraction of the thickness of the base sheet.For example, if a conventional wet press (CWP) base sheet having athickness of 4 mils is being embossed, the clearance can be at leastabout 2-3 mils. If the base sheet is formed by a process which resultsin a web with rather more bulk, such as, for example, a through airdried (TAD) method or by use of an undulatory creping blade, theclearance could desirably be relatively less. Those of ordinary skill inthe art will be able to determine the desired element spacing of thepresent invention based on the factors discussed above using theprinciples and examples discussed further herein.

[0057] As noted above, in one embodiment it is preferred that the heightof the elements 34 be at least about 30 mils, and it is furtherpreferred that the height be from about 30 to 65 mils. Engagement, asused herein, is the overlap in the z-direction of the elements fromopposing embossing rolls when they are engaged to form a perforatingnip. The engagement overlap should be at least 1 mil.

[0058] In one embodiment, the engagement is at least about 15 mils.Various engagements are depicted in FIGS. 12-14. In particular, FIG. 12depicts a 32 mil engagement. That is, the overlap of the elements, inthe z-direction, is 32 mils. The desired engagement is determined by avariety of factors, including element height, element sidewall angle,element spacing, desired effect of the embossing elements on the basesheet, and the base sheet properties, e.g., basis weight, caliper,strength, and stretch. Those of ordinary skill in the art willunderstand that a variety of engagements can be employed based on theabove, as well as other factors. It is preferred that the engagement bechosen to substantially degrade the machine direction tensile strengthof the web. It is further preferred that the engagement be at leastabout 5 mils.

[0059] In one embodiment, where the element height is about 42.5 milsand the elements have sidewall angles of from about 7° to 11°, theengagement range can be from about 16 to 32 mils. FIG. 12 depicts a 32mil engagement, where the element heights are 42.5 mils and the sidewallangles are 7°, 9°, and 11°. It is believed that lower sidewall anglesmake the process significantly easier to run with more controllabilityand decreased tendency to “picking.”

[0060] The element alignment also affects the degradation of the web inthe machine and cross-machine directions. Element alignment refers tothe alignment in the cross-machine direction within the embossingelement pairs when the embossing rolls are engaged. FIG. 4 depicts anembodiment including hexagonal embossing elements having a full stepalignment, i.e., where the elements are completely overlapped in thecross-machine direction. FIG. 5. depicts an embodiment wherein hexagonalembossing elements are in half step alignment, i.e., where the elementsof each element pair are staggered so that half of the engaged portionof their cross-machine direction dimensions overlap. FIG. 6. depicts anembodiment wherein hexagonal embossing elements are in quarter stepalignment, i.e., where the elements of each element pair are staggeredso that one quarter of the engaged portion of their cross-machinedirection dimensions overlap. The embodiment depicted in FIG. 7 is astaggered array, wherein each element pair is in half step alignmentwith adjacent element pairs. Those of ordinary skill in the art willunderstand that a variety of element alignments are available for usewith this invention, depending upon preferred embossing patterns, webstrength requirements, and other factors.

[0061]FIGS. 8-9 depict the effects of various alignments of a hexagonalelement arrangement on a web. In the example depicted in FIG. 8, wherethe elements are in full step alignment, perforations exist only in thecross-machine direction in the area between the element pairs. However,between the pairs of element pairs, occasional machine directionperforations can be caused in the machine direction. The result is adegradation of strength in both the machine and cross-machinedirections. In the example depicted in FIG. 9, the web is embossed byelement pairs in half step alignment. In this example, the perforationsexist primarily in the cross-machine direction, with some minorperforations caused in the machine-direction. Thus, in FIG. 9, machinedirection strength is degraded, and cross-machine direction strength isdegraded to a lesser extent.

[0062] As noted above, the elements can be both in the machine directionand cross-machine direction. FIG. 16 depicts an emboss roll havingcross-machine direction and machine direction hexagonal elements.

[0063] In another embodiment, depicted in FIG. 10, beveled oval elementsare in full step alignment. As with the full step hexagonal elementsdiscussed above, in the area between the element pairs perforationsexist primarily in the cross-machine direction. However, between thepairs of element pairs, perforations can be caused in the machinedirection. The result is a degradation of strength in both the machineand cross-machine directions. In the embodiment depicted in FIG. 11, onthe other hand, where the beveled oval elements in a half step alignmentare employed, the machine direction perforations are substantiallyreduced. In particular, between the elements in half step alignment, theperforation lies primarily in the cross-machine direction. Between theelement pairs, which are in zero step alignment, primarily pinpointruptures exist. These pinpoint ruptures have a minor effect ondegradation of the directional properties of the web.

[0064] Those of ordinary skill in the art will understand that numerousdifferent configurations of the above described element parameters,i.e., element shape, angle, sidewall angle, spacing, height, engagement,and alignment, can be employed in the present invention. The selectionof each of these parameters may depend upon the base sheet used, thedesired end product, or a variety of other factors.

[0065] One factor, which is impacted by these parameters, is “picking”of the web as it is embossed. Picking is the occurrence of fiber beingleft on the embossing roll or rolls as the web is embossed. Fiber on theroll can diminish the runability of the process for embossing the web,thereby interfering with embossing performance. When the performance ofthe embossing rolls is diminished to the point that the end product isnot acceptable or the rolls are being damaged, it is necessary to stopthe embossing process so that the embossing rolls can be cleaned. Withany embossing process, there is normally a small amount of fiber left onthe roll which does not interfere with the process if the roll isinspected periodically, e.g., weekly, and cleaned, if necessary. Forpurposes of the invention, we define picking as the deposition of fiberon the rolls at a rate that would require shut down for cleaning of therolls more frequently than once a week.

EXAMPLES

[0066] The following examples exhibit the occurrence of picking observedin certain arrangements of cross-machine direction perforate embossedpatterns. This data was generated during trials using steel embossingrolls engraved with the cross-machine direction beveled oval embossingpattern at three different sidewall angles. In particular, the embossingrolls were engraved with three separate regions on the rolls—a 7°embossing pattern, a 9° embossing pattern, and an 11° embossing pattern.Two trials were performed. In the first trial, the embossing rolls hadan element height of 45 mils. The base sheet, having a thickness of 6.4mils, was embossed at engagements of 16, 24, and 32 mils. In the secondtrial, the steel rolls were modified by grinding 2.5 mils off the topsof the embossing elements, thereby reducing the element height to 42.5mils and increasing the surface area of the element tops. The base sheethaving a thickness of 6.2 mils was embossed at engagements of 16, 24,28, and 32 mils. For each trial, embossing was performed in both halfstep and full step alignment.

[0067] The element clearances for each of the sidewall angles of thefirst and second trials have been plotted against embossing engagementin Graphs 2 and 3, respectively. The broken horizontal line on each plotindicates the caliper of a single ply of the base sheet that wasembossed. The graphs have been annotated to show whether fiber pickingwas observed at each of the trial conditions (half step observationbeing to the left of the slash, full step observation to the right). Thepicking results are depicted in Graphs 2 and 3 below.

[0068] Graph 2 shows that for this particular trial using embossingrolls having a 45 mil element height, picking did not occur at any ofthe sidewall angles. However, as shown in Graph 3, when the embossingrolls having a 42.5 mil element height were run, fiber picking wasobserved on the 11° sidewall angle elements at the higher embossingengagements, i.e., 24, 28, and 32 mils. No fiber picking was encounteredwith elements having sidewall angles of 7° or 9°.

[0069] Based on the observed data, it appears that picking is a functionof the element height, engagement, spacing, clearance, sidewall angle,alignment, and the particular physical properties of the base sheet,including base sheet caliper. An example of element clearance can beseen in FIG. 12, where the side profiles of the 42.5 mil elements(having 7°, 9°, and 11° sidewall angles) at 32 mil embossing engagementare shown. Clearance is the distance between adjacent engaging embossingelements. As noted above, the caliper of the embossed sheet for thistrial was 6.2 mils. As shown in FIG. 12, the calculated or theoreticalclearance at 7° is 0.004906″ (4.906 mils), the clearance at 9° is0.003911 ″ (3.911 mils), and the clearance at 11° is 0.00311 ″ (3.11mils). Thus, for this trial at a 32 mil engagement, picking was observedonly when the clearance was less than about ½ of the caliper of thesheet. Compare this to the clearances shown in FIG. 13. FIG. 13 depictsthe sidewall profiles of the 42.5 mil elements at 28 mil embossingengagement. In this arrangement, the calculated or theoretical clearanceat 7° is 0.006535″ (6.535 mils), the clearance at 9° is 0.005540″ (5.540mils), and the clearance at 11° is 0.004745″ (4.745 mils). In thistrial, picking was observed when the clearance was less than about ¾ ofthe caliper of the sheet. Note, however, that when embossing at 32 mils,as described above, picking did not occur at 9°, while the clearance wasless than 4.745 mils. FIG. 14 depicts the sidewall profiles of the 42.5mil elements at 24 mil engagement. In this arrangement, the clearance at11° is 0.005599″ (5.599 mils), slightly less than the caliper of thesheet. As shown on Graph 3, picking did occur for these elements, butonly when the elements were in full step alignment and not when in halfstep alignment. And, as shown in Graph 2, picking did not occur at all,at any angle, engagement, or alignment, for the 45 mil embossing rolls.

[0070] Thus, based on the collected data, picking can be controlled byvarying element height, engagement, spacing, clearance, alignment,sidewall angle, roll condition, and the physical properties of the basesheet. Based upon the exemplified information, those of ordinary skillin the art will understand the effects of the various parameters andwill be able to determine the various arrangements that will at leastachieve a non-picking operation, i.e., the configuration required toavoid an unacceptable amount of picking based on the factors discussedabove, and, hence, produce acceptable paper products with a process thatdoes not require excessive downtime for roll cleaning.

[0071] To establish the effectiveness of the various element patterns inperforating the web in the cross-machine direction, and therebydegrading machine direction strength while maintaining cross-machinedirection strength, a test was developed, the transluminance test, toquantify a characteristic of perforated embossed webs that is readilyobserved with the human eye. A perforated embossed web that ispositioned over a light source will exhibit pinpoints of light intransmission when viewed at a low angle and from certain directions. Thedirection from which the sample must be viewed, e.g., machine directionor cross-machine direction, in order to see the light, is dependent uponthe orientation of the embossing elements. Machine direction orientedembossing elements tend to generate machine direction ruptures in theweb which can be primarily seen when viewing the web in thecross-machine direction. Cross-machine direction oriented embossingelements, on the other hand, tend to generate cross-machine directionruptures in the web which can be seen primarily when viewing the web inthe machine direction.

[0072] The transluminance test apparatus, as depicted in FIG. 15,consists of a piece of cylindrical tube 44 that is approximately 8.5″long and cut at a 28° angle. The inside surface of the tube is paintedflat black to minimize the reflection noise in the readings. Lighttransmitted through the web itself, and not through a rupture, is anexample of a non-target light source that could contribute totranslucency noise which could lead non-perforate embossed webs to havetransluminance ratios slightly exceeding 1.0, but typically by no morethan about 0.05 points. A detector 46, attached to the non-angled end ofthe pipe, measures the transluminance of the sample. A light table 48,having a translucent glass surface, is the light source.

[0073] The test is performed by placing the sample 50 in the desiredorientation on the light table 48. The detector 46 is placed on top ofthe sample 50 with the long axis of the tube 44 aligned with the axis ofthe sample 50, either the machine direction or cross-machine direction,that is being measured and the reading on a digital illuminometer 52 isrecorded. The sample 50 is turned 90° and the procedure is repeated.This is done two more times until all four views, two in the machinedirection and two in the cross-machine direction, are measured. In orderto reduce variability, all four measurements are taken on the same areaof the sample 50 and the sample 50 is always placed in the same locationon the light table 48. To evaluate the transluminance ratio, the twomachine direction readings are summed and divided by the sum of the twocross-machine direction readings.

[0074] To illustrate the results achieved when perforate embossing withcross-machine direction elements as compared to machine directionelements, a variety of webs were tested according to the above describedtransluminance test. The results of the test are shown in Table 1. TABLE1 Transluminance Ratios Basis Weight Creping (lbs/ Method Emboss EmbossTransluminance ream) (Blade) Alignment Pattern Ratio 30 Undulatory FullStep CD Beveled Oval 1.074 30 Undulatory Half Step CD Beveled Oval 1.05632 Undulatory Half Step CD Beveled Oval 1.050 30 Undulatory Half Step CDOval 1.047 31 Undulatory Half Step CD Oval 1.044 31 Undulatory Full StepCD Oval 1.043 30 Undulatory Full Step CD Beveled Oval 1.040 32Undulatory Half Step CD Beveled Oval 1.033 30 Undulatory Half Step CDBeveled Oval 1.033 30 Undulatory Full Step CD Oval 1.027 32 UndulatoryHalf Step CD Beveled Oval 1.025 30 Undulatory Half Step CD Oval 1.022 31Undulatory Full Step CD Oval 1.018 20 Undulatory Half Step CD BeveledOval 1.015 30 Undulatory Half Step CD Beveled Oval 1.012 30 UndulatoryFull Step CD Beveled Oval 1.006 28 Standard Unknown MD Perforated 1.00024 Undulatory Half Step MD Perforated 0.988 22 Standard Unknown MDPerforated 0.980 29 Undulatory Half Step MD Perforated 0.966 29Undulatory Half Step MD Perforated 0.951 31 Undulatory Half Step MDPerforated 0.942 29 Undulatory Half Step MD Perforated 0.925

[0075] A transluminance ratio of greater than 1.000 indicates that themajority of the perforations are in the cross-machine direction. Forembossing rolls having cross-machine direction elements, the majority ofthe perforations are in the cross-machine direction. And, for themachine direction perforated webs, the majority of the perforations arein the machine direction. Thus, the transluminance ratio can provide aready method of indicating the predominant orientation of theperforations in a web.

[0076] As noted above, perforated embossing in the cross-machinedirection preserves cross-machine direction tensile strength. Thus,based on the desired end product, a web perforate embossed with across-machine direction pattern will exhibit one of the following whencompared to the same base sheet embossed with a machine directionpattern: (a) a higher cross-machine direction tensile strength atequivalent finished product caliper, or (b) a higher caliper atequivalent finished product cross-machine direction tensile strength.

[0077] Furthermore, the tensile ratio (a comparison of the machinedirection tensile strength to the cross-machine direction tensilestrength—MD strength/CD strength) of the cross-machine perforateembossed web typically will be at or below the tensile ratio of the basesheet, while the tensile ratio of the sheet embossed using prior artmachine direction perforate embossing typically will be higher than thatof the base sheet. These observations are illustrated by the followingexamples.

[0078] Higher cross-machine direction strength at equivalent caliper isdemonstrated in Table 2. This table compares two products perforateembossed from the same base sheet—a 29 pounds per ream (lbs/R),undulatory blade-creped, conventional wet press (CWP) sheet. TABLE 2Increased CD Strength at Equivalent Caliper MD Dry CD Dry Dry TensileEmboss Basis Wt. Caliper Tensile Tensile Ratio (perforate) (lbs/R)(mils) (g/3″) (g/3″) (MD/CD) CD 29.1 144 3511 3039 1.16 Hexagonal MD29.2 140 4362 1688 2.58 Hexagonal

[0079] As shown in Table 2, the cross-machine direction perforateembossed web has approximately the same caliper as the machine directionperforate embossed web (144 vs. 140 mils, respectively), but itscross-machine direction dry tensile strength (3039 g/3″) is considerablyhigher than that of the machine direction hexagonal-embossed web (1688g/3″). In addition, compared to the tensile ratio of the base sheet(1.32), the cross-machine direction perforate embossed web has a lowerratio (1.16), while the machine direction perforate embossed web has ahigher ratio (2.58). Thus the method of the present invention provides aconvenient, low cost way of “squaring” the sheet—that is, bringing thetensile ratio closer to 1.0.

[0080] Higher caliper at equivalent finished product cross-machinedirection tensile strength is illustrated by three examples presented inTable 3. For each example a common base sheet (identified above eachdata set) was perforate embossed with a cross-machine direction and amachine direction oriented pattern (Hollow Diamond is a machinedirection oriented perforate emboss). TABLE 3 Increased Caliper atEquivalent CD Tensile Strength MD Dry CD Dry Dry Emboss Basis Wt.Caliper Tensile Tensile Tensile Ratio (perforate) (lbs/R) (mils) (g/3″)(g/3″) (MD/CD) Base Sheet - undulatory blade-creped, CWP base sheet withtensile ratio = 1.32 CD Quilt 28.8 108 4773 4068 1.17 MD Quilt 28.8  786448 3880 1.66 Base Sheet - undulatory blade-creped, CWP base sheet withtensile ratio = 1.32 CD Quilt 29.5 154 2902 2363 1.23 MD Quilt 29.5 1205361 2410 2.22 Base Sheet - undulatory blade-creped, CWP base sheet withtensile ratio = 1.94 CD Oval 24.6  75 4805 2551 1.88 Hollow 24.1  565365 2364 2.27 Diamond

[0081] In each case, the cross-machine direction perforate embossedproduct displays enhanced caliper at equivalent cross-machine directiondry tensile strength relative to its machine direction perforateembossed counterpart. Also, the cross-machine direction perforateembossed product has a lower tensile ratio, while the machine directionperforate embossed product a higher tensile ratio, when compared to thecorresponding base sheet.

[0082] The current invention further allows for a substantial reductionin base paper weight while maintaining the end product performance of ahigher basis weight product. As shown below in Table 4, wherein the webis formed of recycled fibers, the lower basis weight cross-machinedirection perforate embossed towels achieved similar results to machinedirection perforate embossed toweling made with higher basis weights.TABLE 4 Performance Comparisons. PRODUCT ID 20204 30.5#HD Hollow 22#30C6Hollow 28#29C8 Diamond CD Oval Diamond CD Oval (MD (CD (MD (CD EMBOSSPerforate) Perforate) Perforate) Perforate) BASIS WT (LBS/ 24.1 22.231.3 28.9 REAM) CALIPER 56 62 76 81 DRY MD TENSILE 5365 5057 5751 4144(g/3″) DRY CD TENSILE 2364 2391 3664 3254 (g/3″) MD STRETCH (%) 7.6 8.18.8 10.1 CD STRETCH (%) 6.3 6.1 5.5 5.3 WET MD CURED 1236 1418 1409 922TENSILE (g/3″) WET CD CURED 519 597 776 641 TENSILE (g/3″) MacBeth 310072.3 72.6 73.3 73.4 BRIGHTNESS (%) SAT CAPACITY (g/m²) 98 102 104 119SINTECH MODULUS 215 163 232 162 BULK DENSITY 367 405 340 385 WETRESILIENCY 0.735 0.725 0.714 0.674 (RATIO)

[0083] In Table 4, two comparisons are shown. In the first comparison,an 24.1 lbs/ream machine direction perforated web is compared with a22.2 lbs/ream cross-machine direction perforated web. Despite the basisweight difference of 1.9 lbs/ream, most of the web characteristics ofthe lower basis weight web are comparable to, if not better than, thoseof the higher basis weight web. For example, the caliper and the bulkdensity of the cross-machine direction perforated web are each about 10%higher than those of the machine direction perforated web. The wet anddry tensile strengths of the webs are comparable, while the Sintechmodulus of the cross-machine direction perforated web (i.e., the tensilestiffness of the web, where a lower number is preferred) is considerablyless than that of the machine direction perforated web. In the secondcomparison, similar results are achieved in the sense that comparabletensile ratios and physicals can be obtained with a lower basis weightweb. Paradoxically, consumer data indicates that the 28#29C8 product wasrated equivalent to the 30.5#HD product while the 22#30C6 product was atstatistical parity with the 20204 product, but was possibly slightlyless preferred than the 20204 product.

[0084] This invention can be used in a variety of different processes.The webs in each of the above-described examples were formed in aconventional wet press process. However, the invention is equallyapplicable when the base web is a through air dried web. In addition, toincrease the smoothness of the resulting product, the web may becalendered. Or, as in one of the examples above, to increase thebulkiness of the product, an undulatory creping blade such as describedin U.S. Pat. No. 5,690,788, which is herein incorporated by reference,may be used. Those of ordinary skill in the art will understand thevariety of processes in which the above-described invention can beemployed.

[0085] It is understood that the invention is not confined to theparticular construction and arrangement of parts and the particularprocesses described herein but embraces such modified forms thereof ascome within the scope of the following claims.

What is claimed is:
 1. An embossing system for embossing and perforatingat least a portion of a web comprising: a first embossing roll havingembossing elements; and at least a second embossing roll havingembossing elements, wherein the embossing elements of the first andsecond embossing rolls define perforate nips for embossing andperforating the web; and wherein at least a portion of the perforatenips are substantially oriented in the cross-machine direction.
 2. Theembossing system of claim 1 wherein substantially all of the perforatenips are substantially oriented in the cross-machine direction.
 3. Theembossing system of claim 1 wherein all of the perforate nips aresubstantially oriented in the cross-machine direction.
 4. The embossingsystem of claim 1 wherein at least a portion of the embossing elementsare male elements that are substantially oval shaped.
 5. The embossingsystem of claim 1 wherein at least a portion of the embossing elementsare male elements that are substantially hexagonal shaped.
 6. Theembossing system of claim 1 wherein at least a portion of the embossingelements are male elements that are substantially rectangular shaped. 7.The embossing system of claim 1 wherein the cross-machine embossingelements are at an angle of from at least about 60° to 120° from themachine direction.
 8. The embossing system of claim 1 wherein thecross-machine embossing elements are at an angle of from about 85-95°from the machine direction.
 9. The embossing system of claim 1 whereinat least a portion of the cross-machine embossing elements are maleelements having a height of at least about 15 mils.
 10. The embossingsystem of claim 9 wherein at least a portion of the cross-machineembossing elements are male elements having a height of at least about30 mils.
 11. The embossing system of claim 10 wherein at least a portionof the cross-machine embossing elements are male elements having aheight of about 30 to 65 mils.
 12. The embossing system of claim 9wherein at least a portion of the cross-machine embossing elements aremale elements having a height of at least about 45 mils.
 13. Theembossing system of claim 9 wherein at least a portion of thecross-machine embossing elements are male elements having a height of atleast about 60 mils.
 14. The embossing system of claim 1 wherein thecross-machine embossing elements are in full-step alignment.
 15. Theembossing system of claim 1 wherein the cross-machine embossing elementsare in half-step alignment.
 16. The embossing system of claim 1 whereinthe cross-machine embossing elements are in quarter-step alignment. 17.The embossing system of claim 1 having a cross-machine elementengagement of from about at least 15 mils.
 18. The embossing system ofclaim 1 having a cross-machine element engagement of from about at least16 to 32 mils.
 19. The embossing system of claim 1 wherein thecross-machine embossing elements have angled sidewalls, wherein thesidewalls have an angle of less than about 20°.
 20. The embossing systemof claim 19 wherein the sidewall angle of the cross-machine embossingelements is less than about 17°.
 21. The embossing system of claim 19wherein the sidewall angle of the cross-machine embossing elements isless than about 14°.
 22. The embossing system of claim 19 wherein thesidewall angle of the cross-machine embossing elements is less thanabout 11°.
 23. The embossing system of claim 19 wherein the sidewallangle of the cross-machine embossing elements is from about 7° to 11°.24. The embossing system of claim 1 wherein at least a portion of theelements have a height of about 30 mils and have an engagement of about15 mils.
 25. The embossing system of claim 1 wherein at least a portionof the elements have a height of about 30 mils and have an engagement ofabout 24 mils.
 26. An embossing system for embossing at least a portionof a web comprising: a first embossing roll; and at least a secondembossing roll, wherein each of the first and second embossing rolls hasat least one juxtaposable embossing element substantially oriented inthe cross-machine direction, thereby defining a cross-machine directionperforate nip between the cross-machine direction elements for embossingand perforating the web, and wherein at least a substantial portion ofthe cross-machine direction elements have at least the ends beveled. 27.The embossing system of claim 26 wherein at least a portion of theembossing elements are male elements that are substantially oval shaped.28. The embossing system of claim 26 wherein at least a portion of theembossing elements are male elements that are substantially hexagonalshaped.
 29. The embossing system of claim 26 wherein at least a portionof the embossing elements are male elements that are substantiallyrectangular shaped.
 30. The embossing system of claim 26 wherein thecross-machine embossing elements are at an angle of from at least about60° to 120° from the machine direction.
 31. The embossing system ofclaim 30 wherein the cross-machine embossing elements are at an angle ofabout 85° to 95° from the machine direction.
 32. The embossing system ofclaim 26 wherein at least a portion of the cross-machine embossingelements are male elements having a height of at least about 15 mils.33. The embossing system of claim 32 wherein at least a portion of thecross-machine embossing elements are male elements having a height of atleast about 30 mils.
 34. The embossing system of claim 32 wherein atleast a portion of the cross-machine embossing elements are maleelements having a height of at least from about 30 to 65 mils.
 35. Theembossing system of claim 32 wherein at least a portion of thecross-machine embossing elements are male elements having a height of atleast about 45 mils.
 36. The embossing system of claim 32 wherein atleast a portion of the cross-machine embossing elements are maleelements having a height of at least about 60 mils.
 37. The embossingsystem of claim 26 wherein the cross-machine embossing elements are infull-step alignment.
 38. The embossing system of claim 26 wherein thecross-machine embossing elements are in half-step alignment.
 39. Theembossing system of claim 26 wherein the cross-machine embossingelements are in quarter-step alignment.
 40. The embossing system ofclaim 26 having a cross-machine element engagement of greater than atleast about 15 mils.
 41. The embossing system of claim 26 having across-machine element engagement of between about 16 to 32 mils.
 42. Theembossing system of claim 26 wherein the cross-machine embossingelements have angled sidewalls, wherein the sidewalls have an angle ofless than about 20°.
 43. The embossing system of claim 26 wherein thesidewall angle of the cross-machine direction elements is less thanabout 17°.
 44. The embossing system of claim 26 wherein the sidewallangle of the cross-machine direction elements is less than about 14°.44. The embossing system of claim 26 wherein the sidewall angle of thecross-machine direction elements is less than about 11°.
 45. Theembossing system of claim 26 wherein the sidewall angle of thecross-machine embossing elements is from about 7° to 11°.
 46. Theembossing system of claim 26 wherein at least a portion of the elementshave a height of about 30 mils and have an engagement of about 15 mils.47. The embossing system of claim 26 wherein at least a portion of theelements have a height of about 30 mils and have an engagement of about24 mils.
 48. An embossing system for embossing and perforating at leasta portion of a web comprising: a first embossing roll; and at least asecond embossing roll, wherein each of the first and second embossingrolls has at least one juxtaposable embossing element defining across-machine direction perforate nip between the cross-machinedirection elements for embossing and perforating the web, and wherein atleast a substantial portion of the cross-machine direction elements havesidewall angles of less than about 20°.
 49. The embossing system ofclaim 48 wherein the cross-machine direction elements have sidewallangles of less than about 17°.
 50. The embossing system of claim 48wherein the cross-machine direction elements have sidewall angles ofless than about 14°.
 51. The embossing system of claim 48 wherein thecross-machine direction elements have sidewall angles of from about 7°to 11°.
 52. The embossing system of claim 48 wherein the embossingelements are substantially oval shaped.
 53. The embossing system ofclaim 48 wherein the embossing elements are substantially hexagonalshaped.
 54. The embossing system of claim 48 wherein the embossingelements are substantially rectangular shaped.
 55. The embossing systemof claim 48 wherein the cross-machine embossing elements are at an angleof from at least about 60° to 120° from the machine direction.
 56. Theembossing system of claim 48 wherein the cross-machine embossingelements are at an angle of about 85° to 95° from the machine direction.57. The embossing system of claim 48 wherein the height of thecross-machine embossing elements is from at least about 15 mils.
 58. Theembossing system of claim 48 wherein the height of the cross-machineembossing elements is from at least about 30 mils.
 59. The embossingsystem of claim 48 wherein the height of the cross-machine embossingelements is from about 30 to 65 mils.
 60. The embossing system of claim48 wherein the height of the cross-machine embossing elements is atleast from about 45 mils.
 61. The embossing system of claim 48 whereinthe height of the cross-machine embossing elements is at least fromabout 60 mils.
 62. The embossing system of claim 48 wherein thecross-machine embossing elements are in full-step alignment.
 63. Theembossing system of claim 48 wherein the cross-machine embossingelements are in half-step alignment.
 64. The embossing system of claim48 wherein the cross-machine embossing elements are in quarter-stepalignment.
 65. The embossing system of claim 48 having a cross-machineelement engagement of from greater than about 15 mils.
 66. The embossingsystem of claim 48 having a cross-machine element engagement of at leastabout 16 to 32 mils.
 67. The embossing system of claim 48 wherein atleast a portion of the elements have a height of at least about 30 milsand have an engagement of at least about 15 mils.
 68. The embossingsystem of claim 48 wherein at least a portion of the elements have aheight of at least about 30 mils and have an engagement of at leastabout 24 mils.
 69. A method for embossing and perforating at least aportion of a web comprising: providing a first embossing roll havingembossing elements; and providing at least a second embossing rollhaving embossing elements, wherein at least a predominate number of theembossing elements are substantially oriented in the cross-machinedirection and wherein the first and second embossing rolls define aperforate nip for embossing and perforating the web; and passing the webbetween the first and second rolls wherein the first and secondembossing rolls are configured and the engagement and alignmenttherebetween are controlled to result in an element clearance that willachieve a non-picking clearance while achieving at least a 15% reductionin the machine direction tensile strength of the web.
 70. The method ofclaim 69 wherein the embossing elements are substantially oval shaped.71. The method of claim 69 wherein the embossing elements aresubstantially hexagonal shaped.
 72. The method of claim 69 wherein theembossing elements are substantially rectangular shaped.
 73. The methodof claim 69 wherein the cross-machine embossing elements are at an angleof from about at least 60° to 120° from the machine direction.
 74. Themethod of claim 70 wherein the cross-machine embossing elements are atan angle off about 85° to 95° from the machine direction.
 75. The methodof claim 70 wherein the height of the cross-machine embossing elementsis from at least about 15 mils.
 76. The method of claim 70 wherein theheight of the cross-machine embossing elements is from at least about 30mils.
 77. The method of claim 70 wherein the height of the cross-machineembossing elements is from about 30 to 65 mils.
 78. The method of claim70 wherein the height of the cross-machine embossing elements is atleast from about 45 mils.
 79. The method of claim 70 wherein the heightof the cross-machine embossing elements is at least from about 60 mils.80. The method of claim 70 wherein the cross-machine embossing elementsare in full-step alignment.
 81. The method of claim 70 wherein thecross-machine embossing elements are in half-step alignment.
 82. Themethod of claim 70 wherein the cross-machine embossing elements are inquarter-step alignment.
 83. The method of claim 70 having across-machine element engagement of from at least about 15 mils.
 84. Themethod of claim 70 having a cross-machine element engagement of fromabout 16 to 32 mils.
 85. The method of claim 70 wherein thecross-machine embossing elements have angled sidewalls, wherein thesidewalls have an angle of less than about 20°.
 86. The method of claim70 wherein the sidewall angle of the cross-machine elements is less thanabout 17°.
 87. The method of claim 70 wherein the sidewall angle of thecross-machine elements is less than about 14°.
 88. The method of claim70 wherein the sidewall angle of the cross-machine elements is less thanabout 11°.
 89. The method of claim 70 wherein the sidewall angle of thecross-machine embossing elements is from about 7° to 11°.
 90. A methodfor reducing the tensile ratio of a web by embossing and perforating theweb comprising: passing a web through an embossing system, wherein theembossing system comprises a first embossing roll having embossingelements and at least a second embossing roll having embossing elements,wherein the first and second embossing rolls define a plurality ofperforate nips for embossing and perforating the web; and wherein atleast a predominant number of the perforate nips are substantiallyoriented in the cross-machine direction.
 91. The method of claim 90wherein the tensile ratio of the web is reduced by at least 10% of thedifference between the base web tensile ratio and
 1. 92. The method ofclaim 90 wherein the tensile ratio of the web is reduced by at least 20%of the difference between the base web tensile ratio and
 1. 93. Themethod of claim 90 wherein the tensile ratio of the web is reduced by atleast 30% of the difference between the base web tensile ratio and 1.94. The method of claim 90 wherein substantially all of the perforatenips are substantially oriented in the cross-machine direction.
 95. Themethod of claim 90 wherein all of the perforate nips are substantiallyoriented in the cross-machine direction.
 96. A method for reducing thetensile ratio of a web by embossing and perforating the web comprising:passing a web through an embossing system, wherein the embossing systemcomprises a first embossing roll having at least one embossing elementoriented substantially in the cross-machine direction and at least asecond embossing roll having at least one juxtaposable embossing elementoriented substantially in the cross-machine direction, thereby defininga cross-machine direction perforate nip between the cross-machinedirection elements for embossing and perforating the web; and wherein atleast a substantial portion of the cross-machine direction elements haveat least the ends beveled.
 97. A method for reducing the tensile ratioof a web by embossing and perforating the web comprising: passing a webthrough an embossing system, wherein the embossing system comprises afirst embossing roll having at least one embossing element orientedsubstantially in the cross-machine direction and at least a secondembossing roll having at least one embossing element orientedsubstantially in the cross-machine direction, thereby defining across-machine direction perforate nip between the cross-machinedirection elements for embossing and perforating the web; and wherein atleast a portion of the cross-machine direction elements havecross-machine direction sidewall angles of less than about 20°.
 98. Themethod of claim 97 wherein at least a portion of the cross-machinedirection elements have cross-machine direction sidewall angles of lessthan about 11°.
 99. The method of claim 97 wherein at least a portion ofthe cross-machine direction elements have cross-machine directionsidewall angles of from about 7° to 11°.
 100. A method for reducing thetensile ratio of a web by embossing and perforating the web comprising:passing a web through an embossing system, wherein the embossing systemcomprises a first embossing roll having embossing elements and at leasta second embossing roll having embossing elements, wherein the first andsecond embossing rolls define a perforate nip extending in the crossmachine direction for embossing and perforating the web; and wherein thefirst and second embossing rolls are configured to, and the engagementand alignment are controlled to, result in an element clearance thatwill achieve a non-picking clearance.
 101. The method of claim 69, 90,96, 97, or 100 wherein the web is a creped web.
 102. The method of claim101 wherein the web is creped with an undulatory creping blade.
 103. Themethod of claim 69, 90, 96, 97, or 100 wherein the web is calendered.104. A perforate embossed web having a plurality of cross-machinedirection oriented perforations wherein the embossed web has a tensileratio of less than about 1.2.
 105. A perforate embossed web having atransluminance ratio of at least 1.005.
 106. The perforate embossed webof claim 105 having a transluminance ratio of at least 1.01.
 107. Awet-laid cellulosic perforate embossed web having perforate embossmentsextending predominately in the cross-machine direction.
 108. Thewet-laid cellulosic perforate embossed web having perforate embossmentsextending predominately in the cross-machine direction of claim 107wherein the perforate embossments extend in the cross-machine directionfor at least about 20 mils.
 109. The wet-laid cellulosic perforateembossed web having perforate embossments extending predominately in thecross-machine direction of claim 107 wherein the angle between theperforate embossments extending in the cross-machine direction and themachine direction of the web is between 60° and 120°.
 110. The wet-laidcellulosic perforate embossed web having perforate embossments extendingpredominately in the cross-machine direction of claim 107 wherein saidperforate embossments extend substantially through the thickness of theweb.
 111. The wet-laid cellulosic perforate embossed web according toclaim 105 having a transluminance ratio of at least 1.02.
 112. A methodof embossing and perforating the web comprising: passing a web throughan embossing system, wherein the embossing system comprises a firstembossing roll having embossing elements and at least a second embossingroll having embossing elements, wherein the first and second embossingrolls define a plurality of perforate nips for embossing and perforatingthe web; and wherein the tensile ratio of the web is reduced by at leastabout 5% of the difference between the tensile ratio of the base sheetand 1.0.
 113. The embossing system of claim 1, 26, or 48 wherein atleast a first portion of the cross-machine embossing elements are maleelements having a height of at least about 15 mils and wherein at leasta second portion of the cross-machine embossing elements are maleelements having a height of at least about 15 mils and wherein theheight of the second portion elements is greater than that of the firstportion elements.